Apparatus for producing textiles, nonwoven substances, spunbond fabrics, paper materials, and/or perforated films

ABSTRACT

The invention relates to an apparatus for producing textiles, nonwoven substances, spun-bonded fabrics or paper materials ( 5 ) with the aid of at least one screen drum ( 1 ) having openings ( 4 ) for transporting away the fluid ( 6 ) which is output from a water bar ( 7 ) and having numerous outwardly directed elevations ( 3 ) which are situated on the outside of the screen drum ( 1 ) for the perforation of the nonwoven ( 5 ). The invention is based on the object of providing an apparatus which makes it possible, during the water conversion and at the same time as the perforation, also to make patterns in the nonwoven without influencing the strengthening substantially in the process. The object has been achieved in that one or a plurality of regions ( 8 ) on the outer side of the screen drum ( 1 ) does/do not have any elevations ( 3 ) but only openings ( 4 ).

The object of the invention is an apparatus for producing textiles, nonwovens, spunbond textiles, paper materials and/or perforated films, having at least one foraminous drum formed with holes for transporting away the fluid discharged from a water bar, and having numerous outwardly directed bumps on the outside of the drum for perforating the nonwovens, one or more regions on the outside of the drum not having any bumps, but only holes.

An apparatus for producing perforated nonwovens by means of hydrodynamic needle punching is known from EP 1 001 064 [U.S. Pat. No. 6,324,738], the perforations being formed as substantially sharply defined pores of any dimension in the nonwoven. This apparatus is comprised of a smooth continuous surface carrying and transporting the nonwoven, having drainage holes for transporting away the sprayed on fluid by means of a water bar having multiple discharge nozzles at high pressure, and further having three-dimensional bumps raised from the plane of the smooth surface for producing the perforations in the nonwoven. For this purpose the bumps are nonuniformly distributed across the continuous surface, so they fall at random on the surface of the nonwoven. However, such a system cannot be utilized for embossing patterns, such as animal or plant images, or other geometrically defined shapes in the nonwoven.

U.S. Pat. No. 5,115,544 only shows a method whereby the patterns are pressed into the nonwoven by means of bumps. The bumps, however, are not intended to form the imprint in the nonwoven in the object according to the application, but instead merely surround the pattern to be formed on the foraminous drum.

Furthermore, a method for producing a nonwoven substance is known (DE69224769) [U.S. Pat. No. 5,274,893], where a carrier web (5) is utilized, on whose pattern side a plurality of projections (6, 6′) are provided. The projections (6, 6′) are of large and small sizes. They are made of thermoplastic resin, and are welded onto the pattern side of the web. A quantity of fiber (2) is deposited onto this web (5), which has irregular patterns formed by the projections (6, 6′). Water or hot air is applied under high pressure to the layer of fibers in order to compress them and to felt the fibers. Subsequently, the fibers (2) are pressed onto the projections in order to form patterns in the nonwoven in this manner.

The object of the invention is to provide an apparatus that enables the application patterns simultaneously with the perforation during water needle punching, such as animal or plant images, or other geometrically defined shapes into the nonwoven, without having an adverse effect on the consolidation process. Furthermore, a closed region is formed in the nonwoven, having ventilation holes instead of holes that are distributed across the entire surface of the nonwoven. In the latter case the stability or rigidity of a nonwoven is not obtained to the desired degree. The stability or rigidity of a nonwoven can be substantially improved by means of an advantageous distribution of the nonwoven surface into regions with and without ventilation holes, wherein the patterns are formed particularly by ventilation holes.

The object is attained in that the regions having the bumps, which serve for forming a surface pattern in the nonwoven, such as animals, plants, or geometric shapes, are appropriately arranged or grouped on the drum jacket, and surround, or delimit the surface pattern to be formed on the outside of the drum.

The advantage of this apparatus is particularly that not only are the patterns formed by means of targeted perforation by bumps, or pins, but also that the patterns are created in locations in the nonwoven at which only drainage holes, and no bumps or pins are present. The regions having bumps or pins, cover a preponderant part of the drum surface. In this manner the largest part of the surface of the nonwoven is uniformly stabilized by the perforations formed in the nonwoven by means of the bumps or pins, which are randomly arranged within their respective surfaces. According to this illustrated embodiment the surfaces embodied as a pattern are perforated. It is also possible with the embodiment of the drum surface that the surfaces appearing as a pattern in the nonwoven are not perforated. In this manner the plurality of patterns can be created in the nonwoven in a simple manner.

It is further advantageous that the bumps on the outside of the foraminous drum are at least partially distributed nonuniformly, or are arranged at a different spacing and/or at a uniform spacing from each other.

In an advantageous embodiment holes for the passage of a fluid being discharged from the water bar are provided at least in those regions, in which bumps are provided and/or in those regions, in which no bumps are provided.

It is further advantageous that the bumps have the form of pins on the outside of the drum. In this manner, for example, straight lines, wavy structures, or grid shapes can be created, wherein the pins can be pulled out from the nonwoven without any problems after the formation of the patterns.

In a further embodiment according to the invention it is of advantage that the bumps are embodied such that they are conically tapered toward the outside, or end in a point, or are shaped in the manner of a cylinder.

It is also advantageous that the bumps have a circular, oval, or polygonal or square or elongated cross-section.

For this purpose it is of advantage that the bumps are arranged in the region of a drum jacket having bumps at a spacing of between 1.5 mm and 20 mm, preferably 3 mm to 10 mm.

Furthermore, it is of advantage that the bumps cover an region of the drum jacket of between 20% and 50%, preferably between 25% and 30%.

It is further advantageous that the regions without bumps take up an overall surface of 1% to 50%, preferably between 20% and 50%, or between 25% and 30% of the total surface of the drum.

It is also of advantage that those regions having bumps, and are utilized for forming surface patterns in the nonwoven, such as animals, plants, or geometric shapes, are arranged in an appropriate array or grouping or grouping on the drum jacket. In this embodiment according to the invention the patterns in the nonwoven are created by regions in the nonwoven that are not perforated by the bumps on the drum jacket. It is further advantageous that those regions having no bumps, and those regions having bumps for forming surface patterns, such as animals, plants, or geometric shapes, are arranged in the requisite array or grouping. Those regions having bumps or pins, cover a large part of the drum surface, bring about the desired stability of the nonwoven substance, and simultaneously contribute to the surface patterning of the nonwoven substance.

It is also advantageous that the patterns created in the nonwoven are positioned at least partially, or preponderantly in the plane of the nonwoven, and that the nonwoven has an at least approximately equal thickness, wherein the perforations incorporated in the nonwoven are distributed such that they produce one or multiple equally or differently formed surface patterns in the nonwoven. In a further embodiment of the invention it is of advantage that those regions of the drum jacket having no bumps, and those regions having bumps each form a defined surface.

It is further of advantage that the regions of the drum jacket having no bumps are connected to each other, or surround or contain those regions having bumps.

It is further of particular advantage that the holes in the drum jacket are distributed across the entire surface of the drum jacket in a uniform and/or nonuniform manner, and have a diameter of between 0.1 mm and 3 mm, preferably of between 1 mm and 1.5 mm.

Thus the regions having bumps or pins, cover a preponderant part of the drum surface, bring about the desired stabilization of the nonwovens in the nonwoven, and also simultaneously contribute to the surface patterning of the nonwoven substance.

IN THE FIGURES

FIG. 1 is a detail view of the surface of a drum jacket with and without bumps or pins,

FIG. 2 is a schematic view of a foraminous drum having one or multiple dashed-line water bars for directing jets onto nonwovens,

FIG. 3 is a portion of the surface of the drum jacket having bumps or pins and regions having no bumps,

FIG. 4 is a partial cross-section of the drum according to FIG. 1 having the bumps or pins and an region without bumps,

FIG. 5 a to d are various examples of patterns formed in the nonwoven by means of perforation, or by means of clear regions, where according to FIG. 5 b the perforations delimit the region forming the pattern.

FIG. 1 shows a foraminous drum 1 having a jacket 2 of plastic or metal supported on a cylindrical more rigidly 20 constructed tube 13 by means of support elements 11. The drum jacket 2 thus forms the surface of the drum 1. The drum jacket 2 has holes, drainage holes, or micropores 4 that serve for carrying off the sprayed water from a water jet 6 coming from the water bar 7. The tube 13 simultaneously serves as a suction pipe in order to draw off the water sprayed onto the drum jacket 2, and thus onto the nonwoven. The carrying off of the water is then carried out via an intake hole 12 incorporated in the tube 13 to which suction is applied.

According to FIG. 2 two or more water bars 7 may also be arranged in a second illustrated embodiment about the drum 1. For this purpose a tube 13 not illustrated in the drawing is correspondingly equipped with two or more intake holes 12.

As is obvious particularly from FIGS. 1 and 4, the drum jacket 2 has numerous outwardly directed bumps 3 that serve for perforating the nonwoven 5. These bumps or pins 3 leave the nonwoven 5 with small pores or perforations 14 that are substantially sharply defined and pressed into an already consolidated or partially consolidated nonwoven 5 for this purpose. The perforations 14 in the nonwoven correspond approximately to the cross-sectional size of the pins 3.

The surface of the drum jacket 2 has regions 9, in which the bumps 3 in the form of pins are arranged closely next to each other. The regions 9 having the pins 2 are closed or firmly defined regions. The spacing of the bumps or pins 3 to each other is nonuniform. A stability that is uniform across the surface is achieved in the nonwoven without any interference strips by means of the random arrangement of the bumps or pins 3.

The bumps 3 on the outside of the drum 1, or on the drum jacket 2, are arranged in an nonuniformly distributed manner in the illustrated embodiment illustrated in FIG. 3. However, the bumps may also be arranged at a uniform spacing from each other according to an illustrated embodiment not illustrated in the drawing.

The bumps 3 are formed conically tapered toward the outside, end in a point, or are shaped in the manner of a cylinder. The bumps 3 may have a circular, oval, polygonal, square, or elongated cross-sectional shapes.

The cross-sectional shape of the bumps or pins 3, may also have the be shaped as an involute.

The bumps 3 from the region 9 of the drum jacket 2 are arrayed at a spacing of between 1.5 and 20 mm, preferably 3 to 10 mm. Further, the bumps 3 may cover a region 9 of the drum jacket 2 of between 20% and 50%, preferably between 25% and 30% of the surface.

According to FIGS. 5 a and 5 c, the regions 9 having the bumps 3 in one illustrated embodiment may be used to form a surface pattern, such as animals, plants, or geometric shapes in the nonwoven 5. To this end, a pattern created by perforation of the nonwoven 5 stands out from the remaining, imperforate surface of the nonwoven corresponding to the regions 8.

The regions 8 on the surface of the drum jacket 2, in which no bumps or pins 3, are provided, and also illustrated in FIG. 3 and FIG. 4, are also of particular significance. These regions 8 of the drum jacket 2 are merely provided with the drainage apertures, holes, or micro-pores 4. The regions 8 without bumps 3 take up an overall surface of 1% to 50%, preferably between 20% and 50%, or between 25% and 30% of the total surface area of the drum jacket 2 of the drum 1.

The regions 8 without bumps or pins 3, on the surface of the drum jacket 2, bring about a surface change in the nonwoven 5 during the water needle punching of the nonwoven substance 5 as compared to the perforated surfaces in the nonwoven 5 surrounding the same. For this purpose the regions 8 having no bumps 3 serve for forming a surface pattern, such as animals, plants, or geometric shapes, wherein the regions 8 are surrounded by an appropriate respective array or grouping of pins 3. The regions 8 on the surface of the drum jacket 2 may be arrayed in an isolated manner from each other, or may be connected to each other, thus also creating superordinate patterns in the nonwoven 5.

LIST OF REFERENCE SYMBOLS

-   1 drum -   2 drum jacket and surface of the drum -   3 bumps or pins -   4 holes, drainage holes, micro-pores -   5 nonwoven, nonwoven substance -   6 water jet -   7 water bar -   8 drum jacket without bumps, having holes -   9 drum jacket with bumps, having holes -   11 support elements -   12 intake hole -   13 tube -   14 pores, or perforations, respectively, in the nonwoven 

1. A device for producing textiles, nonwovens, spunbond textiles, paper materials by means of at least one drum having holes for carrying off the fluid discharged from a water bar, and having numerous outwardly directed bumps on the outside of the drum for the perforation of the nonwoven, one or more regions on the outside of the drum having no bumps but merely holes instead, wherein the regions having bumps and serving for forming a surface pattern in the nonwoven are arranged in an array or grouping on the drum jacket and on the surface of the drum surround or delimit the surface pattern to be formed.
 2. The device according to claim 1 wherein the bumps are nonuniformly distributed on the outside of the drum at least partially, or are arranged at different spacings from each other and/or at uniform spacings from each other.
 3. The device according to claim 1 wherein holes at least for the passage of fluid discharged from the water bar are provided on the outside of the drum in regions, in which bumps are provided, and/or in regions, in which no bumps are provided.
 4. The device according to claim 1 wherein the bumps on the outside of the drum are shaped as pins.
 5. The device according to claim 1 wherein the bumps are formed conically outwardly tapered or end in a point, or are shaped as cylinders.
 6. The device according to claim 1 wherein the bumps have a circular, oval, polygonal, square, or elongated cross-section.
 7. The device according to claim 1 wherein the bumps are in a region of a drum jacket having bumps at a spacing of between 1.5 mm and 20 mm.
 8. The device according to claim 1 wherein the bumps cover a region occupying of between 20% and 50% of the drum jacket.
 9. The device according to claim 1 wherein the regions having no bumps take up an overall surface of 1% to 50% , of the total surface of the drum jacket.
 10. The device according to claim 1 wherein the regions having bumps, and being utilized for forming surface patterns in the nonwoven (5), such as animals, plants, or geometric shapes, are arranged on the drum jacket in arrays or groupings.
 11. The device according to claim 1 wherein the regions having no bumps, and the regions having bumps for forming surface patterns are arranged in appropriate arrays or groupings.
 12. The device according to claim 1 wherein the patterns created in the nonwoven are situated at least partially, or preponderantly in a plane of the nonwoven, and that the nonwoven has an at least approximately equal thickness, the perforations incorporated in the nonwoven being distributed such that they produce one or more equally or differently shaped surface patterns in the nonwoven.
 13. The device according to claim 1 wherein the regions of the drum jacket having no bumps, and the regions having bumps each form a defined surface.
 14. The device according to claim 1 wherein the regions of the drum jacket having no bumps are connected to each other, or surround, or contain the regions having bumps.
 15. The device according to claim 1 wherein the holes in the drum jacket are uniformly and/or nonuniformly distributed across the entire surface of the drum jacket, and have a diameter of between 0.1 mm and 3 mm.
 16. An apparatus for making a patterned nonwoven, the apparatus comprising: a pattern drum having an outer surface formed with an array of outwardly projecting bumps delimiting an area on the surface of a shape corresponding to a desired pattern to be formed; means for passing a nonwoven web in a travel direction over the drum with one face of the nonwoven web in contact with an outer surface of the drum; means for directing liquid jets at an opposite face of the web engaged with the drum and thereby pressing the web against the drum, consolidating the web, and pressing the bumps into the one face of the web, whereby a region on the one face into which the pins are not pressed take the pattern; and means for aspirating liquid from the jets through the drum.
 17. The patterning apparatus defined in claim 16 wherein the drum is substantially cylindrical and rotatable about an axis adjacent the means for directing jets.
 18. The patterning apparatus defined in claim 16 wherein the bumps are formed as pins projecting outward from the drum.
 19. The patterning apparatus defined in claim 16 wherein the bumps are nonuniformly distributed in the array.
 20. The patterning apparatus defined in claim 16 wherein the delimited area on the drum surface corresponding to the desired pattern is smooth and devoid of outwardly projecting surface formations. 